Making blanks



i 1 1929. T. E. MURRAY, JR 1,709,185

' MAKING BLANKS Filed May 10, 1926 3 Sheets-Sheet 1- I 72/ 757 P p75 12/ v I T Patented Apr. 16, 1929.

UNITED STATES PATENT OFFICE.

MAKING Application filed May 10,

My invention aims to provide improvements in the production of blanks, particularly though not solely applicable to the making of blanks of sheet metal for use in the 5 production of rear axle housings of automobiles. The accompanying drawings illustrate embodiments of the invention.

Fig. 1 is a rear elevation of an axle hous- Fig. 2 is a cross-section of the same on the line 22;

Fig. 8 is a plan of a blank used in producing the axle housing; I

Fig. & is a plan of a roughly outlined pre- 15 liininary blank from which the finished blank of Fig. 3 is cut;

Figs. 5 and 6 are a plan and side elevation respectively of a unit from which the rough blank of Fig. 1 is formed;

Figs. 7 and 8 are respectively a plan and side elevation of an alternative method; 7

Figs. 9 and 10 are respectively a plan and side elevation of another method;

Figs. 11 and 12 are respectively a plan and side elevation of still another method;

Figs. 13 and 14 are respectively a plan and side elevation of a sheet and method of expanding and cutting it;

Figs. 15 and 16 are respectively a plan and I side elevation of an alternative sheet and method.

Referring to Figs. 1 and 2, the axle housing is made of two tubular end portions 1 with an enlarged central annular portion 2 of channel shape in cross-section through which is a transverse opening 3. The dimensions and proportions of the Various parts difier considerably in practice. The housing is made byfirst forming two segmental blanks each of the full length of the housing, and then uniting them edge to edge by welding along the lines 4.

The segments are bent up from sheet metal strips having a contour of the character indicated in Fig. 3. The end portions 5 of this flat blank are narrow and rectangular. The center portion 6 is slightly wider than the ends in accordance with the requirements for the central portion of the housing. And

ZBLANKS.

1926. Serial No. 107,920.

there are lateral extensions 7 to provide the extra width of metal required for the parts 8, Fig. 1, where the tubular end portions of the housing merge into the annular central portion 2. Obviously the length and width of the parts 5 and 6 and the location and dimensions of the lateral projections 7 will be determined by the shape of the segments desired for making up the housing. A shape of the character shown in Fig. 3 cannot be economically out Whole out of steelsheets of standard sizes. There is a large percentage of Waste or scrap. In previous patents I have proposed to eifect some economy by stamping out the blanks in sections which are afterwards welded together, and other ways. According to the present invention I propose to economize by spreading the metal of a strip so as to pro- Vide lateral extensions on a strip cut in simple rectangular form from the usual sheets.

For example, (see Fig. 4) I may provide a strip of the width indicated at 9 and spread it laterally as at 10 and afterwards out therefrom the blank indicated at 5, 6 and 7 corresponding to Fig. 3. The spreading of the metal as at 10 may be accomplished in a variety of ways shown in the remaining figures.

According to Figs. 5 and 6, two rectangular strips are clamped at the center 11 between stationary electrodes and at the ends 12 between electrodes which, after the metal is heated electrically, are pressed together so as to accumulate extra metal to the ribs 13. The extra metal thus provided is rolled out laterally from the center of the blank to the edge first in one direction and then in the other direction, until the strip resembles the outer contour shown in Fig. 4. The quantity of metal in the ribs can be regulated so as to provide for the lateral extensions 10 without substantial reduction in thickness compared with the thickness of the adjacent rectangular portions 5 and 6; though some variation in thickness is permissible without disadvantage.

Referring to Figs. 7 and 8 a single thickness of metal is bent up to form corrugations 14. The flat portions 15 and 16 being held in fixed clamps, the metal of the corrugations the main portion of the blank.

14 is rolled out laterally first in one direction and then the other. v

According to Figs. 9 and 10 the metal is drawn, and somewhat thinned, to form corrugations 17 entirely within the edges of the strip. The intermediate fiat portion 18 and the end portions 19 are held fixed while the corrugated portions are rolled out in opposite directions laterally as before.

According to Figs. 11 and 12 the strip is stamped or drawn to form corrugations 2Q at the lateral edges. The flat portions 21 and 22 at the center and ends are held fixed While the corrugated portions are rolled out laterally in opposite directions as before.

Figs. 13 and 14 illustrate a sheet from Which a number of strips are to be cut corresponding to those of the previous figures. At one operation depressions or corrugations 23 are formed in the sheet. The latter is then slit along parallel lines 24: into an edge piece A of scrap and full width strips B, C, I), E,

F and so forth. The corrugated portions are then rolled out laterally as before.

Figs. 15and 16 illustrate a similar operation. In this case, however, the corrugations 25 are located between the lines 26 along which the sheet is cut, and the sheet is assumed to be of just sufficient width to form four strips G, H, I and J.

The invention may be applicable not only to the making of blanks of the full length of the housing or similar products but also to the making of blanks for portions or sections which are afterwards welded together to form the complete segments.

In the several schemes illustrated the metal may be heated to any degree necessary or desirable to facilitate the operations described and particularly to facilitate the spreading of the metal in the plane of the blank or of The extra 5 and 6 can be produced in That is,

thickness or r l gs. ordinary rolling mill operations.

strips having corrugations or ribs such as 13 may be bought and these may be cut transversely to form the strip blanks illustrated. in the other figures, there is an extension of the metal in a direction transverse to the plane of the blank, rather than an actual thickening of the metal at these points, but such extensions in the transverse direction can also be produced by rolling mills of known design.

Figs. 13 and 15', for example, may be considered as part of a long strip'rolled in the direction transverse to the lines 24 and 26 with the corrugations formed during such rolling.

' The lateral rolling operation results in a blank of substantially uniform cross-section throughout itswidth in the Zone Where the lateral projections 7 are formed. Conse-' quently, in the finished housing of Fi 1 the metal is of substantially uniform thickness in cross-section where the end tubes merge into or join the central annulus. In these regions the torsional strain in use is very great, and it is important that the metal is distributed evenly in cross-section so as to resist torsional strains evenly all around this part of the housing. 7

Various modifications of the described process may be made by those skilled in the art without departure from the invention as defined in the following claims.

What I claim is:

1. The method of making axle housings and the like having tubular end portions and a central. annular portion which consists in cutting rectangular strips of metal from a sheet, spreading the metal of said strips to form blanks with projections in the plane of the blank and of uniform thickness through- I out its width in the zone of said projections,

bending up said blanks to segmental shape corresponding to one half of the desired housing with said projections at the point where the end portions join the central portion and uniting a pair of such segments edge to edge to form the housing of uniform thickness in the cross-section where the end. tubes joint the central annulus.

2. In the making of segments of axle housings and the like, forming rectangular strips, with corrugated portions, holding the uncorrugated portions in fixed clamps and laterally rolling the corrugated portions so as to form flat blanks with projections in the plane of the blank and with metal of uniform thickness in the zone of saidproj ections and bending up said blanks to segmental shape.

3. In the making of segments of axle housings and the like, providing a strip with an increased quantity of metal per unit of length at points where lateral projections are required, rolling the extra metal thus provided laterallyto form flat blanks with such lateral projections and of uniform thickness in the zones of such projections and bending up said blanks to segmental shape.

4-. In the making of segments of axle housings and the like, providing a strip which is corrugated on both faces at points in its length where lateral projections are desired, spreading the corrugated metal at such points to form flat blanks with such lateral projections and of uniform thickness in the zones of such projections and bending up said blanks to segmental. shape.

5. In the making of segments of axle housings and the like, providing a strip having corrugations on both faces lying entirely within its edges and located at points where lateral projections are required,spreading the corrugated portions of thestrip to form a flat blank with lateral projections and of uniform thickness in the zone of said proflat blanks With such projections and of unijections and bending up such blanks to segform thickness in the zone of said projec- 10 mental shape. tions, trimming such blanks to the outline 6. In the making of segments of axle h0usdesired and bending them up to segmental ings and the like, providing a strip with an shape. increased quantity of metal per unit of length In Witness whereof, I have hereunto signed at points Where lateral projections are remy name. quired, spreading themetal laterally to form THOMAS E. MURRAY, JR. 

